DE102010008890B4 - Engine cylinder head cooling features and methods of training - Google Patents

Abstract

A method comprising: casting a cylinder head (14, 16) having an integral cast-in exhaust manifold (26) defining an intermediate exhaust passage (40) in fluid communication with exhaust passages (38) and an exhaust exhaust passage (42) in fluid communication with the intermediate exhaust passage (40) wherein the cast cylinder head (14, 16) includes a coolant cavity (28) for receiving a cooling fluid, the coolant cavity (28) including first and second portions (46, 48) extending around an outer periphery of the exhaust gas outlet passage ( 42) and are separated by a first potted wall (60); machining the first potted wall (60) to provide fluid communication between the first and second sections (46, 48) of the coolant cavity (28), and Forming a first coolant passage around the outer periphery of the exhaust gas outlet passage (42) characterized by employing a machining center articles (64, 66) in a cast second coolant passage (52) extending through a lower surface (58) of the cylinder head (14, 16) and into the second portion (48) of the coolant cavity (28) prior to machining wherein the second coolant passage (52) provides fluid communication between the coolant cavity (28) and a supply of cooling fluid; andmachining a second potted wall (62) in the cylinder head (14, 16), the second potted wall (62) extending between the first and second portions (46, 48) of the coolant cavity (28) along the outer perimeter of the exhaust outlet passage ( 42), the first coolant passage creating a continuous fluid path around the outer periphery of the exhaust gas outlet passage (42) after machining the second cast wall (62).

Description

AREA

The present disclosure relates to a method of manufacturing a cylinder head.

BACKGROUND

This section provides background information relating to the present disclosure that does not necessarily constitute prior art.

Engine assemblies may include a cylinder head with a molded integral exhaust manifold. Exhaust manifolds that are formed in one piece with a cylinder head can include an exhaust gas outlet that is arranged closer to the exhaust ports of the cylinder head than in conventional exhaust manifolds. The greater proximity of the exhaust gas outlet to the outlet ducts can lead to higher temperatures occurring at the exhaust gas outlet. These higher temperatures can result in increased thermal stresses being applied to the exhaust manifold and even melting of areas of the exhaust manifold such as e.g. B. lead the outlet flange. During these high temperature conditions, portions of the outlet flange that define screw holes can soften, which can result in the sealed engagement between the outlet flange and another component such as a screwdriver. B. reduced a turbocharger manifold.

Out DE 697 16 168 T2 a method of manufacturing a cylinder head according to the preamble of claim 1 is known, the cylinder head having first and second cooling cavities which are connected by two drilled channels. The channels are drilled through openings machined in the outer surface of the cylinder head, which are closed again after drilling. Further cylinder heads and processes for their manufacture are in EP 2 003 320 A1 , DE 692 32 067 T2 and AT 505 591 A2 described.

It is the object of the invention to provide a simple method for producing a cylinder head with a cast-in integrated exhaust manifold.

SUMMARY

The object is achieved by a method with the features of claim 1.

One method of forming a cylinder head may include casting the cylinder head to include an integral cast-in exhaust manifold. The integral molded exhaust manifold may define an intermediate exhaust passage in fluid communication with exhaust passages and an exhaust exhaust passage in fluid communication with the intermediate exhaust passage. The cast cylinder head may include a coolant cavity to receive a cooling fluid. The coolant cavity may include first and second portions that extend around an outer perimeter of the exhaust outlet passage and are separated from one another by a first molded wall. The method may further include machining the first potted wall to create fluid communication between the first and second portions of the coolant cavity. The machining of the first potted wall may form a first coolant passage created by the first and second portions of the coolant cavity and the machined passage around the outer periphery of the exhaust outlet passage.

A cast cylinder head may include an exhaust passage, an exhaust manifold, and a coolant cavity. The exhaust manifold can be in fluid communication with the exhaust port. The exhaust manifold may define an exhaust exhaust passage and an intermediate exhaust passage that provides fluid communication between the exhaust passage and the exhaust exhaust passage. The coolant cavity may include first and second portions that extend around an outer periphery of the exhaust outlet passage. The first and second sections may be in fluid communication with one another via a first machined passageway.

The first and second portions of the coolant cavity may be in fluid communication with one another around an entire outer periphery of the exhaust gas outlet passage.

Further areas of application are evident from the description given here. The description and specific examples in this summary are intended for illustrative purposes only and are not intended to limit the scope of the present disclosure.

Figure list

• 1 ist eine schematische Darstellung einer Motoranordnung gemäß der vorliegenden Offenbarung;
• 2 ist eine perspektivische Ansicht des Zylinderkopfs des Motors von 1;
• 3 ist eine fragmentarische Schnittansicht des Zylinderkopfs von 2 in einem ersten Zustand;
• 4 ist eine fragmentarische Schnittansicht des Zylinderkopfs von 2 und eines ersten Werkzeugs;
• 5 ist eine fragmentarische Schnittansicht des Zylinderkopfs von 2 und eines zweiten Werkzeugs; und
• 6 ist eine fragmentarische Schnittansicht des Zylinderkopfs von 2 in einem zweiten Zustand.

The drawings described herein are for illustrative purposes only and are in no way intended to limit the scope of the present disclosure.

• 1 Figure 3 is a schematic illustration of an engine assembly in accordance with the present disclosure;
• 2 FIG. 13 is a perspective view of the cylinder head of the engine of FIG 1 ;
• 3 FIG. 13 is a fragmentary sectional view of the cylinder head of FIG 2 in a first state;
• 4th FIG. 13 is a fragmentary sectional view of the cylinder head of FIG 2 and a first tool;
• 5 FIG. 13 is a fragmentary sectional view of the cylinder head of FIG 2 and a second tool; and
• 6th FIG. 13 is a fragmentary sectional view of the cylinder head of FIG 2 in a second state.

Corresponding reference characters indicate corresponding parts throughout the several views of the drawings.

DETAILED DESCRIPTION

Examples of the present disclosure will now be described more fully with reference to the accompanying drawings. The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses.

In 1 is an exemplary engine arrangement 10 shown schematically. The engine arrangement 10 can have an engine block 12th , a first cylinder head 14th , a second cylinder head 16 and a valve train assembly 18th include. The engine block 12th may have a V-configuration defining first and second cylinder banks that include first and second sets of cylinder bores 20th defined at an angle relative to each other to form the V-configuration. While shown as a V-configuration, it should be understood that the present disclosure is in no way limited to V-configuration engines. The present disclosure applies equally to a variety of other engine configurations, including, but is not limited to, in-line engines. The first cylinder head 14th may be coupled to the first bank and the second cylinder head 16 can be coupled to the second row.

The engine arrangement 10 can form an inner outlet configuration in which inlet channels 24 on an outside of the first and second cylinder heads 14th , 16 are arranged and outlet channels 38 on an inside of the first and second cylinder heads 14th , 16 are arranged. Although shown as an inner outlet configuration, it should be understood that the present disclosure applies equally to outer outlet configurations.

The first and second cylinder heads 14th , 16 can generally be similar to each other. Hence the first cylinder head 14th with the understanding that the description applies equally to the second cylinder head 16 applies, described below. With additional reference to 2 and 6th can the first cylinder head 14th Inlet ducts 24 , an integrated exhaust manifold 26th and a coolant cavity 28 define. The inlet ducts 24 can generally allow for a flow of air into the cylinder bores 20th to care. The integrated exhaust manifold 26th can with the first cylinder head 14th can be formed as a one-piece casting, as discussed in more detail below. The coolant cavity 28 may receive a cooling fluid from a coolant supply to a desired temperature of the cylinder head 14th during engine operation.

As in 1 can be seen, the valve train assembly 18th Inlet camshafts 30th , Exhaust camshafts 32 , Inlet valves 34 and exhaust valves 36 include. The intake and exhaust camshafts 30th , 32 can on the first and on the second cylinder head 14th , 16 be rotatably supported. The intake camshafts 30th can with the inlet valves 34 are engaged to selectively establish fluid communication between the cylinder bores 20th and the inlet ducts 24 to accomplish. The exhaust camshafts 32 can with the exhaust valves 36 are engaged to selectively establish fluid communication between the cylinder bores 20th and the integrated exhaust manifold 26th to accomplish.

As in 2 and 6th can be seen, the integrated exhaust manifold 26th Outlet ducts 38 , an intermediate exhaust passage 40 , an exhaust outlet 42 and an outlet flange 44 include. The coolant cavity 28 can through the integrated exhaust manifold 26th extend. The coolant cavity 28 can have a first and a second section 46 , 48 include. The first and the second section 46 , 48 can be cast-in features. The first paragraph 46 can be a first circumferential extent of a wall 51 extending the exhaust outlet 42 defined, and the second section 48 can be a second circumferential extent of the wall 51 extending the exhaust outlet 42 Are defined. As in 6th can be seen, the first and the second section 46 , 48 of the coolant cavity 28 in a second (or completed) state, are in fluid communication with each other, extending around an entire perimeter of the wall 51 extending the exhaust outlet 42 Are defined.

A first run 50 can go through an outside wall 54 of the integrated exhaust manifold 26th and in the first section 46 of the coolant cavity 28 extend. The first round 50 can be a thread 56 on an upper portion thereof for engagement with a temperature sensor (not shown). Alternatively, the first pass 50 covered and sealed (not shown). A second pass 52 (in 5 can be seen through a lower surface 58 of the first cylinder head 14th and may form a fluid passage for connection to a coolant supply (not shown). The coolant supply can be a flow of coolant from the engine block 12th and can be metered through an orificed opening designed as a nozzle in a seal (not shown), which is located between the engine block 12th and the first cylinder head 14th is arranged.

The expansion of the coolant cavity 28 around a whole circumference of the exhaust outlet 42 can provide improved cooling for the outlet flange 44 of the integrated exhaust manifold 28 create. As a non-limiting example, the expansion of the coolant cavity 28 the outlet flange 44 maintain below a predetermined temperature to achieve a sealed engagement with a downstream component such as B. a turbocharger manifold (not shown). In particular, the expansion of the coolant cavity 28 generally prevent the area of the outlet flange 44 , the screw holes 45 is defined, soft and / or deformed.

3-5 generally represent the first cylinder head 14th during various stages of training. 3 generally represents the first cylinder head 14th in a first (or initial) state. As in 3 shown is a portion of an initial casting of the first cylinder head 14th with a first and a second wall 60 , 62 that controls the fluid flow between the first and second sections 46 , 48 of the coolant cavity 28 hinder, shown. The first and second walls 60 , 62 can generally be opposed to one another along the outer perimeter of the wall 51 the exhaust outlet 42 be arranged and may be formed at an interface at which a first and a second casting core (not shown) during the casting of the first cylinder head 14th rest against each other. During casting, molten material such as. B. aluminum used to form the first cylinder head 14th is used, expand into the area where the cores abut each other, which forms the first and second walls.

Around the first and second walls 60 , 62 machining operations can be performed. As a non-limiting example, the first and second walls 60 , 62 be drilled as in 4th and 5 to see. In 4th can be a first machining tool 64 the first pass 50 in the first cylinder head 14th form. The first machine tool 64 can with a top surface of the integrated exhaust manifold 26th generally adjacent to the exhaust outlet 42 come into engagement. As a non-limiting example, the first machining tool 64 include a reaming mandrel. The first machine tool 64 can move a distance in the first section 46 of the coolant cavity 28 extend enough to match the first wall 60 to get into engagement. The first machine tool 64 can generally be the first wall 60 remove what is fluid communication between the first and second sections 46 , 48 of the coolant cavity 28 creates.

In 5 can use a second machining tool 66 within the second pass 52 in the first cylinder head 14th to be ordered. As a non-limiting example, the second machining tool 66 include a reaming mandrel. The second pass 52 can during the casting of the first cylinder head 14th be formed. The second machining tool 66 can be at an angle relative to the lower surface 58 of the first cylinder head 14th orientation and can be found in the second section 48 of the coolant cavity 28 extend. The second machining tool 66 can move on to the second section 48 extend a distance sufficient to interfere with the second wall 62 to get into engagement. The second machining tool 66 can generally be the second wall 62 remove what is fluid communication between the first and second sections 46 , 48 of the coolant cavity 28 creates. After machining the first and second walls 60 , 62 by the first and second machining tools 64 , 66 may have a generally continuous flow path between the first and second sections 46 , 48 of the coolant cavity 28 around the entire circumference of the exhaust outlet 42 exist.

Claims (5)

A method comprising: casting a cylinder head (14, 16) having an integral molded-in exhaust manifold (26) defining an intermediate exhaust passage (40) in fluid communication with exhaust passages (38) and an exhaust exhaust passage (42) in fluid communication with the intermediate exhaust passage (40) wherein the cast cylinder head (14, 16) includes a coolant cavity (28) for receiving a cooling fluid, the coolant cavity (28) including first and second portions (46, 48) that extend extending around an outer periphery of the exhaust gas outlet passage (42) and separated from one another by a first molded wall (60); machining the first potted wall (60) to provide fluid communication between the first and second portions (46, 48) of the coolant cavity (28) and forming a first coolant passage around the outer periphery of the exhaust gas outlet passage (42) characterized by Inserting a machining tool (64, 66) into a cast second coolant passage (52) extending through a lower surface (58) of the cylinder head (14, 16) and into the second portion (48) of the coolant cavity (28) machining, the second coolant passage (52) providing fluid communication between the coolant cavity (28) and a supply of cooling fluid; and machining a second potted wall (62) in the cylinder head (14, 16), the second potted wall (62) extending between the first and second portions (46, 48) of the coolant cavity (28) along the outer perimeter of the exhaust outlet passage (42), the first coolant passage creating a continuous fluid path around the outer periphery of the exhaust gas outlet passage (42) after machining the second cast wall (62). Procedure according to Claim 1 wherein the machining comprises drilling. Procedure according to Claim 1 wherein the first coolant passage (50) after machining is continuous around an entirety of the outer periphery. Procedure according to Claim 1 wherein machining the first cast wall (60) comprises forming an opening (50) through an outer wall (54) of the cast exhaust manifold (26) to access the first cast wall (60), in particular the opening ( 50) forms a temperature sensor mounting area, which in particular further comprises the formation of a thread (56) in an inner bore of the opening (50) for engagement with a temperature sensor. Procedure according to Claim 1 , wherein the cast-in outlet manifold (26) comprises an outlet flange (44), wherein the first coolant passage is arranged between the outlet flange (44) and the intermediate exhaust gas passage (40), in particular the first coolant passage is arranged adjacent to the outlet flange (44) around the To cool the outlet flange (44).

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